RRD introduces paper mailers, VOC-free inks to cut plastic use

USA – RRD has introduced a range of sustainable packaging and printing solutions designed to help brands reduce plastic consumption, improve recyclability and minimise environmental impact, including a recyclable paper mailer and a portfolio of inks and coatings replacing conventional plastic laminations.

Among the developments is the VersaPac FastTrack Paper Mailer, a recyclable e-commerce packaging solution featuring a paper peel-and-seal closure that replaces conventional silicone-coated plastic peel strips. 

Designed as an alternative to mixed-material mailers including paper-and-bubble constructions, the product is intended for curbside recycling. 

RRD has also developed a scalable manufacturing process integrating direct-mail production and insertion inline, improving production efficiency.

Vegetable-Oil Inks Eliminate Volatile Organic Compounds

The company expanded its ink offerings with formulations addressing environmental and functional requirements. Its FO2 vegetable-oil-based inks use primarily soybean, rapeseed and palm oil raw materials in place of petroleum-derived ingredients. 

Tested to GB38507-2020 standards, the inks contain no volatile organic compounds, according to RRD, and are designed to support deinking during paper recycling. 

RRD also developed metallic inks as an alternative to conventional foil stamping, providing decorative metallic effects while maintaining deinking performance.

Aqueous Coatings Replace BOPP Film Lamination

RRD is promoting aqueous coatings as alternatives to biaxially oriented polypropylene film lamination for food and beverage packaging, cosmetics and consumer products. 

The coatings deliver premium surface finishes including anti-scratch matte and soft-touch effects while reducing reliance on plastic films. 

According to RRD, replacing conventional plastic lamination with its aqueous coating solutions can reduce greenhouse gas emissions by up to 53 percent and packaging plastic use by more than 90 percent, alongside potential material cost reductions exceeding 10 percent and a 10 percent improvement in recyclable pulp yield.

Scented and Fluorescent Inks Expand Functional Options

Additional innovations include scented inks formulated without intentionally added PFAS or restricted heavy metals, designed to meet International Fragrance Association Category 12 standards, with customised formulations available for food-contact packaging. 

The company’s fluorescent ink technology provides ultraviolet effects that remain invisible under ambient lighting and can be used in UV, flexographic and screen printing applications.

John Marrow, president of RRD Packaging, said the market was no longer satisfied with broad sustainability promises, adding that brands needed engineered solutions bridging the gap between ambitious ESG goals and fast-paced operational needs.

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